Laminated non-woven sheet

ABSTRACT

A LAMINATED NON-WOVEN SHEET IS MADE FROM NON-WOVEN MATS OF MELT-BLOWN THERMOPLASTIC POLYMER FIBERS. THE NON-WOVEN SHEETS MAY BE PRODUCED BY EITHER POINT WELDING OR USING ADHESIVES TO LAMINATE AT LEAST ONE NON-WOVEN MAT HAVING A HIGH STRIP TENSILE STRENGTH TO AT LEAST ONE NON-WOVEN MAT HAVING A HIGH TEAR RESISTANCE SO THAT THE SHEETS HAVE BOTH HIGH STRIP TENSILE STRENGTH AND HIGH TEAR RESISTANCE.

Feb. 6, 1973 J. s. PRENTICE LAMINATED NON -WOVEN SHEET Filed Oct. 9. 1969 FIG.

EXTRUDER HOT AIR I N VENTOR.

JAMES S. PRENTICE FIG.3A.

ATTORNEY.

3,715,251 LAMINATED NON-WOVEN SHEET James S. Prentice, Baytown, Tex., assignor to Esso Research and Engineering Company, Linden, NJ. Filed Oct. 9, 1969, Ser. No. 864,994 Int. Cl. B3211 17/12, 31/04 US. Cl. 156-623 11 Claims ABSTRACT OF THE DISCLOSURE A laminated non-woven sheet is made from non-woven mats of melt-blown thermoplastic polymer fibers. The non-woven sheets may be produced by either point welding or using adhesives to laminate at least one non-woven mat having a high strip tensile strength to at least one non-woven mat having a high tear resistance so that the sheets have both high strip tensile strength and high tear resistance.

BACKGROUND OF THE INVENTION (1) Field of the invention The present invention is directed to laminating a plurality of non-woven mats of melt-blown thermoplastic polymer fibers to produce a non-woven sheet. The nonwoven sheets may be produced by either point welding or using adhesives.

(2) Prior art US. 3,341,394; British Pat. 1,055,187; Wente, Van A.,

Super-fine Thermoplastics, Industrial and Engineering Chemistry, vol. 48, No. 8 (1956), pp. 1342-1346.

SUMMARY OF THE INVENTION BRIEF DESCRIPTION OF THE DRAWINGS 'FIG. 1 is a schematic view of the overall melt-blowing process;

\FIG. 2 is a detailed view in longitudinal cross-section of a die which may be used in the melt-blowing process;

FIG. 3 is a schematic view of a press used in fusebonding a non-woven mat or point welding two mats together;

IEIG. 3A is a schematic view of calender rolls which may be used instead of a press; and

FIG. 4 is a schematic view of a laminated non-woven sheet according to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring to FIG. 1 of the drawings, a thermoplastic polymer is introduced into a pellet hopper 1 of an extruder 2. The thermoplastic polymer is forced through the extruder 2 into a die head 3 by a drive 4. The die head 3 may contain heating plates 5 which may control the temperature in the die head 3. The thermoplastic polymer is then forced out of a row of die openings 6 in the die head 3 into a gas stream which attenuates the thermoplastic polymer into fibers 7 which are collected United States Patent 0 3,715,251 Patented Feb. 6, 1973 ice on a moving collecting device 8 such as a drum 9 to form a continuous mat 10. The gas stream which attenuates the thermoplastic polymer is supplied through gas jets 11 and 12 respectively, which are seen more clearly in FIG. 2. The gas slots 11 and 12 are supplied with a hot gas, preferably air, by gas lines 13 and 14 respectively.

The process may be further understood by considering the details of the die head 3 which is more fully set forth'in FIG. 2. The die head 3 is made up of upper die plate 15 and a lower die plate 16. The thermoplastic polymer is introduced in the back of the die plates 15 and 16 through an inlet 17 as it is forced through the extruder 2 into the back of the die head 3. The thermoplastic polymer then goes into a chamber 18 between the upper and lower die plates 15 and 16 respectively. The facing of the die plate 16 may have milled grooves 19 which terminate in the die openings 6. It is understood, of course, that the milled grooves may be in the lower die plate 16, in the upper die plate 15, or that grooves may be milled in both plates 15 and 16. Still further, if a single plate is used in place of the upper and lower die plates, the grooves may be drilled to produce the die openings 6. An upper gas cover plate 20 and a lower gas cover plate 21 are connected to the upper die plate and lower die plate 15 and 16 respectively to provide an upper air chamber 22 and a lower air chamber 23 which terminate in the gas slots 11 and 12 respectively. The hot gas is supplied through inlet 24 in upper gas cover plate 20 and inlet 25 in lower gas cover plate 21. Suitable bafiling means (not shown) may be provided in both the upper air chamber 22 and lower air chamber 23 to provide a uniform flow of air through the gas slots 11 and 12 respectively. The die head 3 may contain heating means 5 for heating both the thermoplastic polymer and air in the die head 3.

The characteristics of the non-woven thermoplastic polymer mats produced by the melt-blowing process will vary considerably depending upon the particular process conditions used. The characteristics of the non-woven thermoplastic polymer mats are affected in large part by the air flow rates used in the melt-blowing process and the distance of the take-up device from the die openings in the die head. These effects were noted as meltblown non-woven mats were attempted to be made having high strip tensile strength and hightear resistance. However, both high strip tensile strength and high tear resistance were found to be unobtainable in a single melt-blown non-woven thermoplastic polymer mat. Inherent in the present invention is the recognition that to obtained both high strip tensile strength and high tear resistance in a melt-blown non-woven thermoplastic polymer sheet, the melt-blown non-woven mats have to be laminated one to another. Specifically, this invention involves laminating melt-blown non-woven mats having a high strip tensile strength to melt-blown non-woven mats having a high tear resistance.

In the melt-blowing process, when the air rates are high and the pounds of air to pounds of thermoplastic polvmer extruded through the die head are high (suitably greater than about 140, desirably 150, and preferably in excess of 200 lbs. air/lbs. of polymer for polypropylene) the thermoplastic polymer fibers in the non-woven mat are such that generally the mat has a higher zero span tensile strength. The fibers at the higher air rates appear to be drawn, and are much finer fibers as evidenced by their small diameters, which range from 1 to 10 microns.

One of the other process variables in the melt-blowing process which materially afiects the characteristics of the non-woven thermoplastic polymer mat is the distance of the take-up device from the die openings and the die head. When the collecting device is between 1 and 6 inches from the die openings, there is evidence of considerable selfbonding of the fibers as they are laid down in the nonwoven mat. At distances greater than 6 inches between the die openings and collector device, some self-bonding still occurs but the amount of self bond-ing decreases with distance. The term self-bonding herein means thermal bonding of one fiber to another in the melt-blowing process as the non-woven thermoplastic polymer mats are formed. The strip tensile strength of the thermoplastic polymer mats as produced by the melt-blowing process is greatest in those mats having the highest degree of selfbonding, for as the self-bonding decreases, the mat is comprised essentially of entangled fibers and the strip ten sile strength materially decreases. Another factor in the strip tensile strength of the melt blown mat is the tensile strength of the fiber itself. The tensile strength of the fibers in the melt-blown, non-woven mat is found by measuring the zero span tensile strengths of the mats, a measurement which utilizes the same general procedure employed to obtain strip tensile strength of the mats. The procedures for obtaining strip tensile strength and zero span tensile strength are those in ASTM procedure D-828-60, with the exception that to measure the strip tensile strength the clamps are set apart at a distance of 2 inches using an elongation rate of 250% /min., but to measure the zero span tensile strength, the clamps are not separated by any distance. In both instances, the results are reported in meters, the unit resulting when the force necessary to break the mat, measured in grams, is divided by the width of the sample, measured in meters, all of which is divided by the basis weight of the sample in terms of grams/ meter The process variables used in the melt-blown process to obtain mats of high strip tensile strength result in low tear resistances in those mats. correspondingly, when a non-woven mat of high tear resistance is produced, the mat has a low strip tensile strength. The conditions for producing a mat of high tear resistance generally require that the take-up device be positioned at a distance greater than 8 inches fnom the die openings so th'at substantial entanglement of the fibers occurs rather than a large degree of self-bonding. Furthermore, it is desirable to operate at lower air rates and, accordingly, much lower air to polymer rates (generally less than about 50 for polypropylene), to obtain a mat in which the fibers are of a larger diameter-within the range of 10 to 40 microns, usually to 25 microns. The non-wovenmats made of these larger diameter thermoplastic polymer fibers, collected as entangled fibers and containing some self-bonding, have higher tear resistances than the non-woven mats made of interentangled smaller diameter fibers. The tear resistance of the non-woven mat is measured by a standard Elmendorf tear strength tester in accordance with ASTM procedure D 68962.

For use in the laminated sheet of the present invention, the strip tensile strengths of the non-woven mats that are formed by the melt-blowing process are generally lower than desired even though the zero span tensile strength of of the mats may be quite high. Accordingly, the strip tensile strengths are improved by treating the non-woven mats by a fuse-bonding process. The fuse-bonding process may be accomplished by applying a spaced pattern of heat to the mat to melt discrete portions of the mat and fuse a portion of the fibers in the mat. Alternatively, the fusebonding may be effected by a general fusion of the fibers by applying an unbroken pattern of heat to the mat. In the fuse-bonding process, sufiicient pressure is applied to prevent shrinkage of the fibers in the non-woven mat as indicated by measuring the size of the mat before and after fuse-bonding and as determined by a lack of decreztise in the zero span tensile strength of the non-woven ma Referring to a heated press 30 may be used in the fuse-bonding process to increase the strip tensile strengths of the melt-blown non-woven mats. The press 30 comprises a plate 31 and a plate 32. The plate 1 has a plurality of spaced apart projections 33 which terminate in flat lands 34 that are spaced in a design or pattern. The spacing of the projections 33, the total surface of the flat lands 34 and the pattern of the projections 33 of the plate 31 will partially determine the degree to which the fibers of the non-woven mats are point bonded. The spacing of the projections 33 and the pattern may vary greatly although suitable patterns are rectilinear or diagonal grids. Suitable spacing for the projections 33 are between about inch and inch. The depth to which the projections 33 will penetrate the non-woven sheet may be controlled by the use of spacers or shims placed between plate 31 and plate 32. The plate 32 may have a flat surface which would come in contact with the lands 34 of the projections 33 of plate 31 or the plate 32 may also have projections which are aligned with the projections of plate 31 so that the lands of the projections of plate 32 would contact the lands 34 of the projections of plate 31. To obtain higher increases in the strip tensile strengths of the nonwoven mats, he deeper penetration of the projections 33 into the non-Woven mats is desired. Each of the plates 31 and 32 may be heated independently so that the temperatures of the plates are not necessarily the same.

In the fuse-bonding process of the nonwoven mats, it is convenient to use spacer sheets between the non-woven mats and the plates 31 and 32 of the press to prevent the non-woven mat from sticking to the plates either during or subsequent to the fuse-bonding operation. Suitable spacer sheet material which may be employed include insulating materials such as tissue paper, ordinary paper and the like or heat conducting materials such as aluminum foil and the like. The conducting spacer sheets are preferred since the additional heat increases the fusing of the fibers in the fuse-bonding process.

For the continuous production of the non-woven mats of improved higher strip tensile strengths, it is advantageous to carry out the fuse-bonding process by calendering the non-Woven mats under heating conditions which elfect fiber-to-fiber fusion under pressure sufficient to prevent shrinkage of the fibers of the non-woven mat. Referring to FIG. 3A, calender rolls 40 and 41 are shown which may be employed instead of the press 30. The calender roll 40 may have projections which terminate in flat lands which may be patterned in a wide variety of forms, such as a diagonal grid (not shown). In the calendering operation to carry out the fuse-bonding, spacer sheets may also be used to prevent the non-woven mats from sticking to the calender rolls.

According to the present invention, a non-woven laminated sheet is produced from at least one mat of thermoplastic polymer fibers having a high strip tensile strength and at least one mat of the same thermoplastic polymer fiber having a high tear resistance, so that the laminated sheet has both a high strip tensile strength and high tear resistance. The lamination may be accomplished by using an adhesive or by a point-welding process. The lamination is carried out to an extent that the melt-blown non-woven mat having the high strip tensile strength and the meltblown non-woven mat having the high tear resistance each contribute their properties to the non-woven laminated sheet in the approximate proportion of the weight fractions of each of the melt-blown non-woven mats.

The use of an adhesive to accomplish the lamination is preferred when a woven laminated sheet having low delamination characteristics is desired. Suitable adhesives for laminating one melt-blown non-woven mat to another are such contact cements as the nitrile, SBR or polyisobutylene rubber types. When using an adhesive, usually the adhesive is applied to one surface of one of the melt-blown non-woven mats, the other mat is then placed in contact with the adhesive coating, and the mats are pressed together. Of course, the adhesive may be applied to su f of each of the melt-blown non-woven mats and the coated surfaces placed in contact with one another for accomfluorochloroethylene. The specific melt-blown non-woven plishing the lamination. After the non-woven mats are mats used in the examples which follow are illustrative of coated with the adhesive and the mats are contacted one the present invention and utilize the non-woven mats of with the other, they may be passed through a plain surmelt-blown polypropylene fibers produced in accordance faced calender roll to compress them together to form the with the conditions set forth in Table I, which follows. non-woven laminated sheet of the present invention. The melt-blowing process used is that which was illus- An alternative method of laminating the melt-blown nontrated in FIGS. 1 and 2 of the drawings with the specific woven mats to form the non-woven laminated sheets of operating conditions as set forth in Table I. The specific the present invention is to point weld the mats together. non-woven mat characteristics are also set forth in Table The point-welding process is essentially the Same as the I as to basis weight, zero span tensile strength and the deprocess for fuse-bonding a single mat except that in the gree of uniformity of the mat in terms of the zero span point-welding process there are at least two mats present, tensile strength by the ratio of the cross direction to maat least one melt-blown non-woven mat having a high strip chine direction (CD/ MD).

TABLE I Mat; Number A B o D E F G H 1 J K L M N o P Q Polypropylene MFR 0.6 0.6 0.6 0.6 30 30 0.6 0.6 0.6 0.6 0.6 0.6 Extrudortemperature 692 663 702 720 700 690 685 642 640 691 691 690 690 Dietemperature 637 630 643 642 636 631 630 610 600 634 631 633 632 Polymer rate (gm/min.) 8.4 8.0 8.0 8.0 8.1 8.1 8.1 8.2 8.2 8.4 8.4 8.4 8.4 Air fiow'(lb./min.) 4.30 3.85 3. 78 4.24 4.06 4.06 3.90 4.2 4.2 4.36 4.32 4.18 4.16 Lb. air/lb. polymer 232 218 214 240 227 227 218 233 233 235 233 226 224 Screen distance (in.) 4.0 6.0 6.0 6.0 4.0 4.0 4.0 4.0 4.0 3.0 6.0 8.0 12.0 Mat characteristics:

Basis weight m/m2) 66 58 6s 66 60 47 4s 70 50 59 61 64 60 Zero span tensile 6,130 4,580 6,440 6,340 5,230 5,920 6,640 6,600 6,490 5,830 4,820 4,730 4,730 CD/MD 0.64 0.67 0.62 0.76 0.67 0.61 0.62 0.75 0.59 0.73 0.86 0.82

tensile strength and at least one other melt-blown non- EXAMPL S 1 15 woven mat having a hlglh f f if; 30 Laminated non-woven sheets of the present invention F h .non'woven e S 9 t fig are illustrated by the examples set forth in Table II heremvent1 n Illustrated wit i {na 5 9 2 inafter. The laminated sheets are prepared by the laminagetherthe non'woven mat avmg 1g Stnp tenslBe tion of a melt-blown non-woven mat of polypropylene strellgth i the othe.r melt' lown t ag mat fibers having high strip tensile strength to a melt-blown havmg a hlgh tear reslstance- The pomt'we mg Process non-woven mat of polypropylene fibers having high tear may be accomplished either by using a press such a resistance. The lamination is carried out either by pointtrated in FIG. 3, or by calendermg. The laminatlon of the welding the mats together (Examples 1 12) by using sheets is accomplished in the point-welding process by fusan adhesive (Examples ing fibers in each of the melt-blown mats at the interface The norbwoven mats f polypropylene fib having of the superimposed mats. Shims or spacers (not shown) high strip tensile Strength are prepared either by point. y be used to Pemllt the p l t of elthel the P F bonding (Examples 1-9) or by calendering (Examples or the c len rolls to penetrate to a depth Permlttmg 10-15) under conditions as set forth in Table II. The

fusion of the fibers at the interface of the melt-blown nonpoint.bonding or calendering is carried out on a woven mats. woven mat, identified by a capital letter, which was made In the Point-Welding Process, the melt-blown non-Woven under the conditions of Table I. The non-woven mats af- IIlat B having the high tear resistance is most sllhlect to ter being treated to obtain the high strip tensile strength change in its properties by a heating of the non-woven m were then laminated to melt-blown non-woven mats having t0 high temperatures. Accordingly, it is Preferred that the high tear resistance (Mats P and Q of Table I). The renon-woven mat B having the gh tear resistance e sulting laminated non-woven sheet properties are also set placed in contact with the projections of the press 01' f rthi T bl II,

calender rolls instead of in contact with the flat P In Examples 1-9 the melt-blown non-woven mats plate or calender roll, and that the temperature of the (Mats A-D of Table I) have the strip tensile strength plate of the press or the calender rolls having the pr i improved by fuse-bonding utilizing a press wherein the lllOllS be operated at lower temperatures than the flat press temperatures of the plates of the press are separately Plat6 of calender roll- III the P ldi g pr p controlled. The temperatures of the plates are set forth in sheets may be used and in this operation the spacer sheets bl 11 the upper plate being a Smooth f d plate which prevent the sticking of the non-woven mat to the and the lower plate having projections arranged in a press plate or calender rolls may be either the same spaced pattern. In Examples 14 the non-woven mats prodifferent materials. Accordingly, a heat insulating material d d i accordance ith th diti i T bl I were such as a paper or tissue paper may be used in Conta t fuse-bonded to improve the strip tensile strengths of the with the high tear resista ce non-Woven at B, Whereas mat by using two spacer sheets of tissue paper between the spacer sheet between the non-woven mat A having the non-woven mat and the plate having the projections a high strip tenslle strength may be a conducting material and one spacer sheet of aluminum foil between the nonsuch as aluminum foil. These variations are pointed out woven at and the smooth surfaced plate of a press. In merely to emphasize that the physical properties of t e Example 5 a spacer sheet of aluminum foil was placed on melt-blown non-woven mats are attempted to be preserved each side of the non-woven mat in the fuse-bonding. In at a high level 1n the lamination process. Examples 6-9 a single spacer sheet of aluminum foil was The present mventron is illustrated with non-Wove used between the non-woven mat and the smooth surfaced mats formed of melt-blown polypropylene fibers. HoW- plate of the press and a single spacer sheet of tissue paper ever, other thermoplasfic polymer fibers may be used i was used between the non-woven mat and the plate having the present invention and include other polyolefins such projections, I h f E l 1 9 th fu e-bonding as polyethylene; polyesters, including poly(methylmethwas carried out for 10 seconds with the plates being closed acrylate) and poly(ethylene te rephthalate); polyamides so that there was a spacing of 0.005 inch between the such as poly(hexamethylene adipamide), poly (w-caprolands of the projections and the smooth surfaced plate.

amide) and poly(hexamethylene sebacamide); polyvinyls The spacing is provided b a 0 005 nch h b such as polystyrene; and other polymers such as polytriplates. y 1 S m etween the The non-woven mats (Mats E-I of Table I) in Examples 10-15 are calendered to improve the high strip tensile strength of the mats. The non-woven mats are pressed through heated calendering rolls at a rate of 20 feet per minute under a roller pressure of 700 p.l.i. at calender roll temperatures as set forth in Table II.

In Examples 1-12 the laminated non-woven sheet was made by the point-welding process. The same press was employed in the point-welding process as was used to accomplish the fuse-bonding of a single non-woven mat to improve strip tensile strength. The temperatures of the plates of the press are set forth in Table II. In Examples TABLE II Example Number Improve strip tensile strength:

Mats A B C D A Press plate temperatures:

Upper F.) 285 292 290 291 290 Lower F.) 303 308 295 298 298 Lamination conditions.

M B+P C+P D+P A+P Tensile (m.) 4, 219 3, 985 3,928 4,050 Tear resistance (dm. 714 562 421 773 597 Example Number Improve strip tensile strength:

Mats B B C 0 Press plate temperatures:

Upper F 297 295 300 298 Lower F 288 290 290 288 Lamination conditions:

Mats B+P B+P C+P C+P Point-Welding press temperatures:

Upper F. 303 300 300 301 Lower F.) 227 230 231 230 Laminated sheet properties:

Tensile m.) 4, 160 4,077 5, 125 4, 794 Tear resistance (dmfl) 579 860 463 584 Example Number Improve strip tensile strength:

Mats E F G Calender roll temperatures:

Upper F.) 300 305 305 Lower F.) 250 250 250 Lamination conditions Mats E+I I "+P G+P Point-welding press temperatures:

Upper F 278 280 275 225 240 240 s: Tensile (m.) 4, 268 4, 218 4, 474 Tear resistance (dmfl) 796 641 930 Example Number 13 14 1 5 Improve strip tensile strength:

Mats H I H Calender roll to Upper F 305 305 310 Lower F 250 250 255 Lamination conditions:

Mats H+P" I+P H'+Q Adhesive Laminated sheet properties:

Tensile (m.) 4, 685 5,061 5,109 Tear resistance (dmfl) 952 513 90 3 Nora-Prime indicates non-woven mat after treatment to improve strip tensile strength as indicated in specific example; Mat H ealendered three times at indicated temperatures; Mat P ealendered at room temperature, 700 p.l.i., ttJmin.

1-4 the high strip tensile strength mat was placed on the lower plate and the high tear resistance mat was contacted by the upper plate. Tissue paper was used as the spacer sheets in all instances. In Examples 5-12 the high tear resistance mat was placed on the lower plate and the upper plate contacted the high strip tensile strength mat. Again, tissue paper was used as the spacer sheets. In each of Examples 1-12 the point welding was carried out for 10 seconds. In Examples 1-6, the plates were closed to a spacing of 0.005 inch; in Examples 7-9, a spacing of 0.006 inch; and in Examples 10-12, a spacing of 0.008

used to unite the mats making up the laminate, and this is the preferred way to form the laminated non-woven sheets, especially when a high peel strength or resistance to delamination is desired. The point-welded laminated non-woven sheets had a very low peel strength of about 0.5 lb./inch, and were embossed with the imprint of the plate. On the other hand, the adhesive laminates had smooth surfaces and a very high peel strength; the high tear layer yielded before delamination of the layers occurred.

EXAMPLES 16-20 In these examples, Examples 16-20 illustrate the inverse relationship between strip tensile strength and tear resistance which is obtained in melt-blown non-woven mats. The strip tensile strengths and tear resistances were measured for five non-Woven mats that were made by melt-blowing polypropylene under essentially identical conditions (see Table I), except that the die-to-collector distance (D-C-D) was varied. The results are presented While improved strip tensile strength was obtained in the as made melt-blown non-woven mat by using a short die-to-collector distance (Example 16), the tear resistance of this non-woven mat is exremely low, and conversely,

10 at the highest calender roll temperature as well as at an intermediate temperature shows that suflicient pressure was applied to prevent shrinkage of the fibers of the mat. Also to be noticed is the decrease in tear resistance of the non-woven mat as the strip tensile strength is improved.

That the point-bonding technique is effective to increase the strip tensile strength of other non-woven mats produced as non-woven Mat I of Example 21 is illustrated by Examples 22-28.

EXAMPLES 22-28 Various non-woven mats made under melt-blowing conditions which produce fibers that have a diameter between about 1 and 10 microns (see Table I) were point-bonded at elevated temperatures to fuse-bond the fibers of the mat. The fuse-bonding was accomplished with the press and plates of Examples 1-15. The plates were heated to the temperatures set forth in Table V. The fuse-bonding was carried out for 10 seconds, with the mats being closed to a spacing of 0.005 inch between the smooth-surfaced upper plate and the lands of the projections on the lower plate. Except for :Example 26, two sheets of tissue paper were used between the non-woven mats and the lower plate, and one sheet of foil was used between the nonwoven mats and the upper plate. Example 26 had two sheets of foil between it and the lower plate and two sheets of foil between it and the upper plate. The pointbonded non-woven mats, as shown in Table V, exhibited high strip tensile strengths. The strip tensile strengths were greatly increased from the strip tensile strength of the untreated mat.

as the tear resistance was improved (Example 20') the strip tensile strength became extremely low.

EXAMPLE 21 This example illustrates how the strip tensile strength of a non-woven mat is increased by fuse-bonding the mat.

Samples of non-woven Mat I, made under melt-blowing conditions which produce fibers that have a diameter from about 1 to 10 microns (see Table I), were calendered once at heated calender roll temperatures ranging from 200 F. to 320 F. under a roller pressure of 700 p.l.i. at a line speed of 20 feet/ minute, using the calender rolls of Examples 10-14. The results are tabulated in Table IV.

TABLE IV.EXAMPLE 21 Calender roll temperatures:

Together, Examples 21-28 illustrate some of the strip tensile strengths which can be produced at tear resistances less than about 300 dm.

As evidenced by Mats M, P and Q of Table I, meltblown non-woven mats can be produced which have high tear resistances but low strip tensile strengths. The highly tear resistant mats made under melt-blowing conditions which produce larger diameter fibers, such as Mats P and Q, can be treated to produce non-woven mats of increased strip tensile strengths while maintaining a high mat tear resistance. To do this, the mats are fuse-bonded, either by calendering or point-bonding, at temperatures preferably no greater than 275 F., under pressures sufiicient to prevent fiber shrinkage, as exemplified in Examples 29 and 30.

S trip tensile (m.) 2, 346 2, 250 2, 150 2, 600 3, 100 4, 900 5, 600 5, 600 Tear resistance (dm. 44 22 29 Zero span tensile (m.) 5, 490 6, 560 7,130

.As shown by Table IV, calender roll temperatures of 250 F. or greater were effective in increasing the strip tensile strength of non-woven Mat I. The lack of decrease,

EXAMPLES 29-30 Samples of Mats P and Q were calendered at the temindeed, even an increase, of zero span tensile strength 75 peratures and pressures set out in Table VI. Calender roll pressure was 700 p.l.i. and calender roll line speed was 20 feet/min.

The tear resistances of the as-made non-woven Mats M, P and Q, and the tear resistances of the treated nonwoven Mats P and Q of Examples 29 and 30 illustrate higher ranges of tear resistances which can be produced at tensile strengths less than about 2000 m.

As will now be apparent, the laminated non-woven sheets of the present invention have structural properties making them well suited for applications requiring both high tensile strength and high tear resistance, such as heavy duty bags and shipping sacks, carpet backing, fabric backing and other liners and clothing components, synthetic paper, wrapping materials and the like.

Having fully and particularly described the non-woven sheet and the processes involved in this invention and having set out the best modes thereof, it Will be appreciated that alterations and changes may be made by those skilled in the art which are nevertheless within the spirit and scope of the invention, as defined by the appended claims.

I claim:

1. A process for making a strong tear-resistant, nonwoven sheet having a strip tensile strength of at least 400 dmfi, which comprises the steps of:

(a) forming at least two dissimilar non-woven mats (A) and (B) comprised of the same thermoplastic polymer fibers and made by a melt-blown process, but having major differences in tear strength and tensile strength properties; and

(b) bonding at least one mat (A) to at least one mat wherein said mat (A) has a strip tensile strength greater than 5000 m. and a tear resistance of less than 300 dmfi, and wherein said mat (A) has been prepared with air/ polymer rates of more than 140, has a relatively high degree of selfbonding and has a fiber diameter of from 1 to microns;

and said mat (B) has a tear resistance of at least 1000 dm. and a tensile strength of less than 2000 m. and wherein said mat (B) has been prepared with air to polymer rates of less than 50, has fiber diameters of about 10 to 40 microns and is relatively low in self-bonding but high in entanglements.

2. The process of claim 1 in which said mat ,(A) having the greater strip tensile strength comprises bonded fibers having diameters between about 1-10 microns, and said mat (B) having the greater tear resistance comprises fibers that are bound together essentially by entanglement.

3. The process of claim 1 in which said mat (A) comprises self-bonded fibers.

4. The process of claim 1 in which said mat (A) comprises fuse-bonded fibers.

5. The process of claim 1 in which said fibers in said mat (A) and (B) are polypropylene fibers.

6. The process of claim 1 in which said mats are bonded by point-welding said mat (A) and said mat (B) together at a fusing temperature sufficient to fuse the fibers of said mat (A) to the fibers of said mat (B).

7. The process of claim 1 in which said mats are bonded mats, and contacting said mat surface carrying said adhesive with a surface of the other of said mats.

8. A process for making a non-woven sheet from nonwoven mats of melt-blown polypropylene fibers, comprisbonding together a plurality of non-woven mats of melt-blown polypropylene fibers, at least one of said mats (A) having a strip tensile strength greater than 4000 m. and being comprised of fibers having diameters between 1-10 microns, and at least one other of said mats (B) having a tear resistance greater than 400 dm.

9. A process according to claim 8 wherein the non- Woven mats are bonded by point-Welding the Webs wherein said mat having the high strip tensile strength is heated at temperatures between about 270 to about 320 F. and said mat having a tear resistance greater than 400 dm. is heated at temperatures between about 200 to about 245 F.

10. A process according to claim 9 wherein said mat having a strip tensile strength greater than 4000 m. is pressed against a fiat plate at temperatures between about 280 to about 300 F.

11. A process according to claim 8 wherein the non- Woven mats are bonded by applying an adhesive to the surface of one of said mats and contacting said mat surface carrying said adhesive with a surface of the other of said mats.

References Cited UNITED STATES PATENTS 3,148,101 9/1964 Allman, Jr., et al. 156-306 X 3,251,727 5/1966 Reynolds et al 156-291 X 3,254,694 6/1966 Sparks et al. 156-306 X 3,354,020 11/1967 Copeland 156-273 X 3,405,674 10/1968 Coates et a1. 161-120 X 3,420,724 1/ 1969 Saunders 156-306 X 3,468,096 9/1969 Franz 156-290 X 3,341,394 9/1967 Kinney 161-168 X 3,314,840 4/1967 Lloyd et a] 156-244 UX OTHER REFERENCES Wente, Van. A. Super-fine Thermoplastics, Industrial and Engineering Chemistry, vol. 48, No. 8 (1956), pp. 1342-46.

CARL D. QUARFORTH, Primary Examiner E. E. LEHMANN, Assistant Examiner US. Cl. X.R. 

